Slide 3:

Penn University, USA Food Product Innovation Management :

Penn University, USA Food Product Innovation Management A problem-based interdisciplinary capstone learning experience designed to enhance career skills (critical thinking, decision making, team work, communication, etc.) in the context of industry's approach to developing new and improved food products.
The first quarter of the course is devoted to facilitating team work and analyzing an industrial foodproduct development case study.
Students are organized into 4-5 person teams. Each team examines a new product opportunity and prepares a comprehensive plan for developing the product. Written and oral reports are made to the class (simulating management) and/or food industry professionals. In addition, each team studies a decision case based on an industry food product development problem. Role playing is encouraged.
Each case is designed with interactive activities and learning scenarios. They are intended to provide opportunities for students to simulate "real-life" experiences.
http://cas.psu.edu/docs/casover/aefs497/main.html

Scale up :

SCALE-UP :

SCALE-UP Definition
Act of using results obtained from laboratory studies for designing a prototype and a pilot plant process; construction a pilot plant and using pilot plant data for designing and constructing a full scale plant or modifying an existing plant ??——????????????,????????????;??????????????????????,????????????

Problems in Scale up an Food Production Processes :

Problems in Scale up an Food Production Processes Fundamental knowledge of chemical and physical interactions among complex ingredients is either scarce or non-existent
There is usually a lack of data of physical properties for complex food formulations (specific heat capacities, thermal conductivities, phase relationship, rheology, etc) ???????????????????????????
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Steps in Scale-Up(1) :

Steps in Scale-Up(1) Define product economics based on projected market size and competitive selling and provide guidance for allowable manufacturing costs
Conduct laboratory studies and scale-up planning at the same time
Define key rate-controlling steps in the proposed process
Conduct preliminary larger-than-laboratory studies with equipment to be used in rate-controlling step to aid in plant design ?????????,?????,????????????,??????????
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Steps in Scale-Up(2) :

Steps in Scale-Up(2) Design and construct a pilot plant including provisions for process and environmental controls, cleaning and sanitizing systems, packaging and waste handling systems, and meeting regulatory agency requirements
Evaluate pilot plant results (product and process) including process economics to make any corrections and a decision on whether or not to proceed with a full scale plant development ??????????,?????????????????????????????,?????????
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Why conduct Pilot Plant Studies? :

Why conduct Pilot Plant Studies? A pilot plant allows investigation of a product and process on an intermediate scale before large amounts of money are committed to full-scale production
It is usually not possible to predict the effects of a many-fold increase in scale
It is not possible to design a large complex food processing plant from laboratory data alone with any degree of success ?????????????????,??????????????????????
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A pilot plant can be used for :

A pilot plant can be used for Evaluating the results of laboratory studies and making product and process corrections and improvements
Producing small quantities of product for sensory, chemical, microbiological evaluations, limited market testing or furnishing samples to potential customers, shelf-live and storage stability studies ??????????,??????????????????
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A pilot plant can be used for :

A pilot plant can be used for Determining possible salable by-products or waste stream requiring treatment before discharge
Providing data that can be used in making a decision on whether or not to proceed to a full-scale production process; and in the case of a positive decision, designing and constructing a full-size plant or modifying an existing plant ??????????????????????
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Considerations in pilot plant development :

Considerations in pilot plant development Kind and size – depends on goals; evaluating product and process; producing samples of product for evaluation; market testing or furnishing to potential customers
Location: near R&D facility? At an existing plant? Close liaison between R&D and pilot plant staff is essential ?????——?????;???????;????????????????
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Considerations in pilot plant development :

Considerations in pilot plant development Labor requirements and costs: engineering staff, skilled operations and maintenance staff- pilot plant costs may exceed those of usual plant production costs.
The pilot plant may be used for training personnel for a full- scale plant ???????:??????????????????????????????
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Similitudes in scale-up :

Similitudes in scale-up Chemical- often impossible to determinine rate limiting reactions in food system
Diffusion and temperature can be important and not always comparable at different scales ??—??????????????,??????????
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Slide 106:

Slide 107:

PRODUCT PERFORMANCE TEST?????? :

PRODUCT PERFORMANCEOBJECTIVES :

PRODUCT PERFORMANCEOBJECTIVES To understand the factors that control the performance of a food product
To know when, where, how and what to evaluate to determine performance ????????????
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PRODUCT PERFORMANCE :

PRODUCT PERFORMANCE What to control?
What to measure?
How to do it?
Where to do it?
When to do it?
Use of results? ?????
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PRODUCT PERFORMANCE TESTING :

PRODUCT PERFORMANCE TESTING Based on identification of major attributes
Based on identification of safety factors –cpp
Based on identification of quality factors
Based on identification of shelf-life factors ?????????
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TESTING METHODS :

TESTING METHODS Performance tests are generally not research tests
Research methods may be used to solve problems encountered with product
Need to be simple, low cost and provide essential information
Need to establish frequency of testing
Need to establish tolerances for results ???????????
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Basic Types of Tests :

Basic Types of Tests Paired Comparison
Used when benchmark products are available
Which do you prefer and why?
Monadic
Used for unique products
How much do you like it?
Proto-monadic – Combines the above ????
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BASES TESTS – A. C. NEILSEN :

BASES TESTS – A. C. NEILSEN First, obtain Consumer’s reaction to the concept only
Then have them try the product ???????????????
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Questions to Ask Respondents :

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70% ???????
65% ??
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Key Takeaways - Consumer Testing Module :

Key Takeaways - Consumer Testing Module The consumer or customer is ALWAYS right.
Product Development should use consumer guidance testing to determine how to further improve new products before Market Research tests.
Do not let Marketing use guidance testing to make marketing decisions ???????
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Product Development Review :

Product Development Review ??????

PROJECT LIFE-CYCLE PHASES :

ATTRIBUTES ?? ?? :

ATTRIBUTES ?? ?? An attribute is a property of a food that the customer desires
Most customers are looking for multiple attributes in a food product
Attributes are expected to remain constant throughout the shelf-life of the product ??????????;???????;????????

FORMULATION :

FORMULATION “The heart of any new product is in its ingredient composition
Initial screening and feasibility testing required
Select a starting “recipe”
Transfer to a product formula
Test compatibility with process ???????????;??????????;??????;??????;????????????

INGREDIENTS :

INGREDIENTS In almost all formulated foods, every ingredient will have an influence on both the processing requirements and on the final characteristics of the finished product
Need to understand ingredient interactions ????????????????????????????????????????

PROCESS :

PROCESS Use “hurdle” concepts in developing the process
Consider the effects of shear, temperature and time on prodcut attributes
In many foods every step in the process may affect product characteristics
Roll of processing aids ????????“??”??;???????????????????????;????????????????

PROCESS FLOW SHEET :

PROCESS FLOW SHEET Develop a process flow sheet that indicates each step in the process
Indicate conditions for each step in the process
What are the tolerances for the conditions?
Consider materials balance - yield
Process control? Records? ????????????(??)??;?????????????;???????;????;????????

SCALE-UP ?? :

SCALE-UP ?? Is complex and not intuitive
Is generally a step-wise approach from lab to pilot plant to intermediate to full production scale
Requires careful attention to enginerring details ???????;???—??—??—??;???????????

SCALE-UP :

SCALE-UP Reqires tecnology assessment
Learn on a small scale before you try to produce on a large scale
The lab and pilot plant provide design data, engineering methods first indication of formuation processing interactions ????;???????,??????;????????????,???????????????????

SCALE-UP :

SCALE-UP Requires complete understanding of factors that influence product characteristics
Can not be done on paper
Involves technology translation and transfer from r&d to production ?????????????;????????????;?????????????????